Catalyst Components Based on Ferricinium Complexes Used for Olefin Polymerization

ABSTRACT

The present invention discloses catalyst components based on ferricinium ligands, their method of preparation and their use in the polymerisation of olefins.

The present invention discloses catalyst components based on ferriciniumligands, their method of preparation and their use in the polymerisationof olefins.

In the search for new catalyst components capable of producing highlytunable polymers, some ferrocene complexes have been known to polymeriseor co-polymerise ethylene such as for example the ferrocene-substitutedbis(imino) pirydine iron and cobalt complexes disclosed by Gibson et al.in Gibson V. C., Long N. J., Oxford, P. J., White A. J. P., and WilliamsD. J., in Organometallics (ASAP article DOI: 10.1021/om0509589), or forexample the ferrocene-substituted bis(imino) nickel and palladiumcomplexes disclosed by Gibson et al. in J. Chem. Soc. Dalton Trans.2003, 918-926.

They carried out an oxidation of the metallic complex resulting from themetallation of the ferrocene complex. This complex was used in thepolymerisation of ethylene and showed the same level of activity as thenon-oxidised equivalent metallic complex.

There is a need to develop new catalyst system having good activity andable to produce polymers tailored to specific needs.

It is an aim of the present invention to prepare new catalyst componentsthat can be used in the polymerisation of olefins.

It is also an aim of the present invention to provide very activecatalyst components.

It is another aim of the present invention to provide a method forpolymerising or copolymerising olefins.

The present invention reaches, at feast partially, any one of thoseaims.

Accordingly, the present invention discloses a ferricinium ligand offormula

wherein Cp is a cyclopentadienyl group, unsubstituted or substituted,with chelating arms,wherein X and Y are the same or different with the restriction that atleast one Y or X contains at least one chelating group in directconnection with the ferricinium, the other of Y or X being optionallypresent,wherein Z and W are each independently selected from alkyl, aryl,heterocycle group or non-heterocycle group containing ether, thioether,phosphine, imine, amine or amide,wherein iron has been oxidated with an oxidant capable to oxidateFe^(II) into Fe^(III) but mild enough to preserve the ligand, andwherein A⁻ is an anion associated to Fe^(III).

The ligands of the present invention satisfy two conditions:

-   -   The oxidation reaction of ferrocene into ferricinium is        reversible.    -   The oxidation reaction does not destroy the ligand.    -   The oxidised ligand can react with metal precursors to produce        corresponding complexes.

In a preferred embodiment according to the present invention, X and/or Yare each independently selected to include atoms O, N, P, S or groups—CR═CR—, —CR═N—, —N═CR— or —C≡C— wherein R is H, alkyl or aryl groupshaving at most 20 carbon atoms. The link between Y and Z and/or X and Wcan present a conjugation or not.

More preferably, the groups Y—Z and/or X—W are each independentlyselected from CH═N—CH2-Ar wherein Ar is phenyl, furyl or pyridine group.

Most preferably there is only one substituent group Y—Z or X—W, theother being hydrogen.

The most preferred complex according to the present invention is

The oxidation reaction can be carried out chemically orelectrochemically.

In a preferred embodiment according to the present invention, it iscarried out chemically with a mild oxidant. The oxidant is selected inorder to have a potential from 550 to 900 mV versus calomel reference.Among the most preferred oxidants, one can cite iodine. It has apotential of about 600 mV and thus does not destroy the ligand. Inaddition, the reduced form of the oxidant and the oxidant itself areeasily separated and removed from the oxidised ligand.

The oxidised ligand is isolated before complexation with the metal.

The present invention also discloses a method for preparing the oxidizedligand that comprises the steps of:

-   -   a) dissolving the ferrocene ligand into a solvent;    -   b) adding iodine to the solution;    -   c) stirring the mixture at a temperature of from 20 to 80° C.        and during a period of time of from a few minutes to 12 hours;    -   d) evaporating the solvent;    -   e) washing with appropriate solvent to separate the reduced form        of the oxidant and/or excess of the oxidant itself from the        oxidised ligand.    -   f) retrieving the oxidised ligand.

Preferably the oxidation reaction is carried out at room temperatureovernight. The preferred solvent is polar and dissolves all reactionproducts, more preferably, it is acetonitrile (MeCN).

The following scheme can for example be used.

FcL→FcL ⁺+electron×2

I ₂+2 electrons→2I ⁻×1

2FcL+I ₂→2[Fc ⁺ L,I ⁻]

The ligand is then complexed with the metal by complexation reactionwith a metallic precursor M(Hal)_(n)R′_(v-n) in a solvent, wherein M isa metal Group 6 to 10 of the Periodic Table, each Hal is the same ordifferent and is halogen, each R′ is the same or different and issubstituted or unsubstituted hydrocarbyl having from 1 to 20 carbonatoms, substituted or unsubstituted aryloxy or alkoxy, v is the valenceof M and n is zero or an integer at most equal to v.

Preferably M is Ni, Co, Fe, Pd or Cr.

Preferably Hal is chlorine.

Preferably n is equal to v.

The solvent may be selected from dichloromethane or tetrahydrofuran andthe complexation reaction is carried out at room temperature or atreflux.

Typically, two types of metallic complexes could be formed, one wherethe metal is coordinated to one ligand and one where the metal iscoordinated to two ligands. The relative amounts of each ligand andmetal unit depend upon the nature of ligand and of the metal. The amountof ligand must therefore be of at least one equivalent of ligand permetallic equivalent.

The present invention further discloses an active catalyst systemcomprising the metallic complex and an activating agent having anionising action.

Suitable activating agents are well known in the art. The activatingagent can be an aluminium alkyl represented by formula AlR⁺ _(n)X_(3-n)wherein R⁺ is an alkyl having from 1 to 20 carbon atoms and X is ahalogen. The preferred alkylating agents are triisobutyl aluminium(TIBAL) or triethyl aluminium (TEAL).

Alternatively, it can be aluminoxane and comprise oligomeric linearand/or cyclic alkyl aluminoxanes represented by formula

for oligomeric, linear aluminoxanes and by formula

for oligomeric, cyclic aluminoxane,wherein n is 1-40, preferably 10-20, m is 3-40, preferably 3-20 and R*is a C₁-C₈ alkyl group and preferably methyl.

The amount of activating is selected to give an Al/M ratio of from 100to 3000, preferably of about 1000.

Suitable boron-containing activating agents may comprise atriphenylcarbenium boronate such astetrakis-pentafluorophenyl-borato-triphenylcarbenium as described inEP-A-0427696, or those of the general formula [L′-H]+[B Ar₁ Ar₂ X₃ X₄]—as described in EP-A-0277004 (page 6, line 30 to page 7, line 7). Theamount of boron-containing activating agent is selected to give BIMratio of from 0.5 to 5, preferably of about 1.

In another embodiment, according to the present invention, the metalliccomplex may be deposited on a conventional support impregnated with anactivating agent. Preferably, the conventional support is silicaimpregnated with methylaluminoxane (MAO). Alternatively, it can be anactivating support such as fluorinated alumina silica.

The present invention further discloses a method for preparing an activecatalyst system that comprises the steps of:

-   -   a) providing an oxidized ferricinium ligand;    -   b) complexing the ligand of step a) with a metallic salt        M(Hal)_(n)R′_(v-n) in a solvent;    -   c) retrieving a catalyst component;    -   d) activating the catalyst component with an activating agent        having an ionising action;    -   e) optionally adding a cocatalyst;    -   f) retrieving an active oligomerisation or polymerisation        catalyst system.    -   Alternatively, in step d), the catalyst component is deposited        on a support impregnated with an activating agent.

The cocatalyst may be selected from triethylaluminium,triisobutylaluminum, tris-n-octylaluminium, tetraisobutyldialuminoxaneor diethyl zinc.

The active catalyst system is used in the oligomerisation and in thepolymerisation of ethylene and alpha-olefins.

The present invention discloses a method for the oligomerisation or thehomo- or co-polymerisation of ethylene and alpha-olefins that comprisesthe steps of:

-   -   a) injecting the active catalyst system into the reactor;    -   b) injecting the monomer and optional comonomer;    -   c) maintaining under polymerisation conditions;    -   d) retrieving the oligomers and/or polymer.

The pressure in the reactor can vary from 0.5 to 50 bars, preferablyfrom 5 to 25 bars.

The polymerisation temperature can range from 10 to 100° C., preferablyfrom 50 to 85° C.

Preferably the monomer and optional comonomer are selected fromethylene, propylene or 1-hexene.

The present invention also discloses the polymers obtained with the newcatalyst systems.

EXAMPLES

All reactions were performed using standard Schlenk techniques or in anargon-filled glove-box. The starting materials and reagents, purchasedfrom commercial suppliers, were degassed and purified by distillationunder nitrogen using standard drying agents.

Preparation of Ligands. Synthesis of N-ferrocenylidenebenzylamine (F1)

All complexes were prepared according to the method described forexample in Gibson et al. (Chem Soc Rev., 2004, 33, 313-328) or inSamuelson et al. (Journal of Organometallic Chemistry, 1999, 575,108-118).

300 mg (1.4 mmol) of solid ferrocenecarboxaldehyde were introduced in aschlenk. 90 μL (2.1 mmol) of benzylamine and 2 mg of p-toluene sulfonicacid were added. The mixture was dissolved in 20 mL of toluene and thehomogeneous mixture was stirred and heated at reflux overnight (16 h).The solution was cooled down to room temperature (25° C.) and thesolvent was vaporised under vacuum. After drying overnight under vacuumand at a temperature of 50° C., 374.7 mg (1.28 mmol) of orange solidwere obtained with a yield of 91%.

RMN¹H (200 MHz, CDCl₃): δ 8.26 (s, CH═N, 1H); 7.4-7.3 (m, ArH, 5H); 4.73(m, C₅H₄, 2H); 4.69 (s, CH₂Ph, 2H); 4.31 (m, C₅H₄, 2H); 4.20 (s, C₅H₅,5H)

Synthesis of N-ferrocenylidenefurfurylamine (F2)

300 mg (1.4 mmol) of solid ferrocenecarboxaldehyde were introduced in aschlenk. 138 μL (2.1 mmol) of furylamine and 2 mg of p-toluene sulfonicacid were added. The mixture was dissolved in 20 mL of toluene and thehomogeneous mixture was stirred and heated at reflux overnight (16 h).The solution was cooled down to room temperature and the solvent wasvaporised under vacuum. After drying overnight under vacuum and at atemperature of 50° C., 381 mg (1.30 mmol) of orange solid were obtainedwith a yield of 93%.

RMN¹H (200 MHz, CDCl₃): δ 8.20 (s, CH═N, 1H); 7.39 (m, H_(fur), 1H);6.35 (m, 1H); 6.26 (m, H_(fur), 1H); 4.68 (m, C₅H₄, 2H); 4.61 (s, CH₂,2H), 4.39 (m, C₅H₄, 2H); 4.18 (S, C₅H₅, 5H).

Synthesis of N-ferrocenylidenepyridinylmethanamine (F3)

300 mg (1.4 mmol) of solid ferrocenecarboxaldehyde were introduced in aschlenk. 138 μL (2.1 mmol) of aminomethylpyridine were added. Themixture was dissolved in 20 mL of toluene and the homogeneous mixturewas stirred and heated at reflux overnight (16 h). The solution wascooled down to room temperature and the solvent was vaporised undervacuum. After drying overnight under vacuum and at a temperature of 50°C., 379 mg (1.25 mmol) of orange solid were obtained with a yield of89%.

RMN¹H (200 MHz, CDCl₃): δ 8.58 (m, H_(pyr), 1H); 8.34 (s, CH═N, 1H);7.68 (m, H_(pyr), 1H); 7.38 (m, H_(pyr), 1H); 7.17 (m, H_(pyr), 1H),4.80 (s, CH₂, 2H); 4.70 (m, C₅H₄, 2H); 4.40 (m, C₅H₄, 2H); 4.18 (s,C₅H₅, 5H).

Oxidation of Ligands. Synthesis of iodine salt ofN-ferrocenylidenebenzylamine (F1+)

374.7 mg (1.28 mmol) of ligand F1 were dissolved in 40 mL ofacetonitrile. 325 mg (1.28 mmol) of iodine were added. The homogeneousmixture was stirred at room temperature overnight (16 h). The solventwas vaporised under vacuum and the resulting precipitate was washedthree times with 30 mL of diethylether and dried overnight under vacuum.486.2 mg (1.15 mmol) of dark blue solid were obtained with a yield of90%. The compound was diamagnetic.

Synthesis of iodine salt of N-ferrocenylidenefurfurylamine (F2+)

381 mg (1.30 mmol) of ligand F2 were dissolved in 40 mL of acetonitrile.330 mg (1.30 mmol) of iodine were added. The homogeneous mixture wasstirred at room temperature overnight (16 h). The solvent was vaporisedunder vacuum and the resulting precipitate was washed three times with30 mL of diethylether and dried overnight under vacuum. 507.3 mg (1.20mmol) of dark blue solid were obtained with a yield of 92%. The compoundwas diamagnetic.

Synthesis of iodine salt of N-ferrocenylidenepyridinylmethanamine (F3+)

379 mg (1.25 mmol) of ligand F3 were dissolved in 40 mL of acetonitrile.325 mg (1.28 mmol) of iodine were added. The homogeneous mixture wasstirred at room temperature overnight (16 h). The solvent was vaporisedunder vacuum and the resulting precipitate was washed three times with30 mL of diethylether and dried overnight under vacuum. 459.8 mg (1.06mmol) of dark solid were obtained with a yield of 85%. The compound wasdiamagnetic.

Complexation of Oxidised Ligands with Metallic Precursors.

Complexation of oxidised ligand N-ferrocenylidenebenzylamine (F1+) WithCrCl₂.

2.46 mg (20 μmol) of metallic precursor CrCl₂ were introduced in aschlenk. 16.9 mg (40 μmol) of oxidised ligand F1+ were added. The solidswere dissolved in 200 μL of tetrahydrofuran (THF) to reach aconcentration of 0.1 mol/L. The solution was stirred at room temperaturefor a period of time of 3 h and the solvent was vaporised. A dark solidwas obtained.

With CrCl₃.

7.49 mg (20 μmol) of metallic precursor CrCl₃.3THF were introduced in aschlenk. 16.9 mg (40 μmol) of oxidised ligand F1+ were added. The solidswere dissolved in 200 μL of tetrahydrofuran (THF) to reach aconcentration of 0.1 mol/L. The solution was stirred at room temperaturefor a period of time of 3 h and the solvent was vaporised. A dark solidwas obtained.

Complexation of oxidised ligand N-ferrocenylidenefurfurylamine (F2+)With CrCl₂.

2.46 mg (20 μmol) of metallic precursor CrCl₂ were introduced in aschlenk. 16.9 mg (40 μmol) of oxidised ligand F2+ were added. The solidswere dissolved in 200 μL of tetrahydrofuran (THF) to reach aconcentration of 0.1 mol/L. The solution was stirred at room temperaturefor a period of time of 3 h and the solvent was vaporised. A dark solidwas obtained.

With CrCl₃.

7.49 mg (20 μmol) of metallic precursor CrCl₃.3THF were introduced in aschlenk. 16.9 mg (40 μmol) of oxidised ligand F2+ were added. The solidswere dissolved in 200 μL of tetrahydrofuran (THF) to reach aconcentration of 0.1 mol/L. The solution was stirred at room temperaturefor a period of time of 3 h and the solvent was vaporised. A dark solidwas obtained.

Complexation of oxidised ligand N-ferrocenylidenepyridinylmethanamine(F3+) With CrCl₂.

2.46 mg (20 μmol) of metallic precursor CrCl₂ were introduced in aschlenk. 17.4 mg (40 μmol) of oxidised ligand F3+ were added. The solidswere dissolved in 200 μL of tetrahydrofuran (THF) to reach aconcentration of 0.1 mol/L. The solution was stirred at room temperaturefor a period of time of 3 h and the solvent was vaporised. A dark solidwas obtained.

With CrCl₃.

7.49 mg (20 μmol) of metallic precursor CrCl₃.3THF were introduced in aschlenk. 16.9 mg (40 μmol) of oxidised ligand F3+ were added. The solidswere dissolved in 200 μL of tetrahydrofuran (THF) to reach aconcentration of 0.1 mol/L. The solution was stirred at room temperaturefor a period of time of 3 h and the solvent was vaporised. A dark solidwas obtained.

Polymerisation of Ethylene.

The metallic complexes obtained in the previous step were acticated with1000 equivalents with respect to metal Cr of methylaluminoxane (MAO) 30%in toluene.

The addition of total MAO was carried out in two steps:

-   -   1. as activator; and    -   2. as scavenger, mixed with toluene.

The catalyst component was deposited in a schlenk and 3.25 mL of MAOwere added to the schlenk as activating agent (1000 equivalents). Thesolution was stirred for 5 minutes and then diluted with 1.75 mL oftoluene.

The reactor was dried under nitrogen at a temperature of 110° C. for aperiod of time of 30 minutes. The temperature was raised to 35° C. and50 mL of toluene were added to the reactor under nitrogen reflux. Asolution of scavenger consisting of 1 ml of MAO at 30% and 4 mL oftoluene were added to the reactor and the solution was stirred during afew minutes. 20 μmol of the selected catalyst component were added tothe reactor under nitrogen reflux. The nitrogen flux was stopped, thereactor was purged and placed under an ethylene pressure of 15 bars.Stirring was continued for a period of time of one hour. The reactor wasthen purged and the polymerisation was stopped by addition of a 10%solution of MeOH/HCl. The polymer was washed three times with 30 mL ofacetone and dried under vacuum overnight at room temperature. Theresults are displayed in Table 1.

TABLE 1 Metal Activity DSC salt Ligand Kg(PE)/mol(cata)/h Tm ° C. CrCl₂F1+ 91.6 136 CrCl₃ F1+ 77.5 135 CrCl₂ F2+ 67.2 138 CrCl₃ F2+ 45.2 137CrCl₂ F3+ 848 137 CrCl₃ F3+ 269 135

The volume of ethylene consumed has been studied as a function of timeunder the following conditions: 5 μmol of catalyst, 1000 equivalents ofMAO, ethylene pressure of 15 bars, temperature 35° C., 60 mL of toluene.Overt a period of time of 3 hours, the total amount of ethylene consumedis of 8.51 g amounting to 1703 kg of ethylene per mole of catalyst. Thesystem is selective to the polymerisation of ethylene with no or verylittle oligomers. The consumption curve is substantially linear duringthe 3 hours of observation.

The influence of temperature and pressure on the activity have beenstudied on the complex prepared from 1 equivalent of CrCl₂ and 2equivalents of ligand F3+ (5 μmol of catalyst, 1000 equivalents of MAO,t=1 hour and 60 mL of toluene). The results are displayed in Table 2.

TABLE 2 Activity kgPE/mol cata/h T ° C. P = 15 bars P = 24 bars P = 45bars 25  594 (739)* 1966 (1976) 2400 35 1200 (1230) 1800 (1850) 2600 55353 880 (824) — 85 170 714 (674) —

It can be concluded that the activity increases with increasing pressureand decreases with increasing temperature with an optimum temperature of35° C. Decreasing the temperature below 35° C. did not lead to furtherimprovement in activity but indicates the presence of oligomers.Increasing the pressure above 24 bars further improves the activity butthe system reaches a plateau in activity after a polymerisation time of20 to 30 minutes, implying that not enough ethylene is present in thesystem.

The amount of catalyst was then decreased to 1 μmol instead of the 5μmol used in the previous example. The conditions were as follows: 1μmol of catalyst, 1000 equivalents of MAO, p=24 bars, t=1 hour, T=25°C., 60 mL of toluene. After a period of time of 1 hour, 1.6 g ofpolyethylene were obtained with na activity of 1607 kgPE/mol cata/hour.The ethylene consumption was of 3413 kgC2/mol cata/hour, indicating aconsumption larger than the activity. It is postilated that thecatalytic system became favourable to the production of oligomers.

Metallic complexes prepared from 1 equivalent of CrCl₂ and 1 equivalentof ligand F3+ were not as active as those prepared from 2 equivalent ofligand per equivalent of metallic salt. They had an activity of about500 kgPE/mol cata/hour.

Polymerisation of Propylene.

Propylene has been polymerised with a catalyst component resulting fromthe complexation of 1 equivalent of CrCl₂ with 2 equivalents of ligandF3+. The polymerisation conditions were as follows: 5 μmol of catalyst,1000 equivalents of MAO, P=5 bars, T=25° C., t=1 hour, 60 mL of toluene.After a reaction time of 1 hour, no polymer was obtained but 1066 kg ofpropylene were consumed per mole of catalyst per hour resulting in theproduction of oligomers.

1. An ferricinium ligand of formula

wherein Cp is a cyclopentadienyl group, unsubstituted or substituted,with chelating arms, wherein X and Y are the same or different with therestriction that at least one Y or X contains at least one chelatinggroup in direct connection with the ferricinium, the other of Y or Xbeing optionally present and wherein X and/or Y are each independentlyselected to include atoms O, N, P, S or groups —CR═CR—, —CR═N—, —N═CR—or —C≡C— wherein R is H, alkyl or aryl groups having at most 20 carbonatoms, wherein Z and W are each independently selected from alkyl, aryl,heterocycle group or non-heterocycle group containing ether, thioether,phosphine, imine, amine or amide, wherein iron has been oxidated with anoxidant capable to oxidate Fe^(II) into Fe^(III) but mild enough topreserve the ligand, and wherein A⁻ is an anion associated to Fe^(III).2. The oxidised ligand of claim 1 wherein groups Y—Z and/or X—W are eachindependently selected from CH═N—CH2-Ar wherein Ar is phenyl, furyl orpyridine group.
 3. The oxidised ligand of claim 1 wherein there is onlyone substituent group Y—Z or X—W, the other being hydrogen.
 4. Theoxidised ligand of claim 1 wherein oxidation is carried chemically. 5.The oxidised ligand of claim 4 wherein the oxidant has a potential offrom 500 to 900 mV related to calomel reference.
 6. A method forpreparing the oxidised ligand of claim 1 that comprises the steps of a)dissolving a ferrocene ligand into a solvent; b) adding iodine to thesolution; c) stirring the mixture at a temperature of from 20 to 80° C.and during a period of time of from a few minutes to 12 hours; d)evaporating the solvent; e) washing with appropriate solvent to separatethe reduced form of the oxidant and/or excess of the oxidant itself fromthe oxidised ligand. f) retrieving the oxidised ligand. 7-13. (canceled)